Method of making composite panels for metal furniture



Oct. 16, 1928.

J. STANDER METHOD OF MAKING-COMPOSITE PANELS FOR METAL FURNITURE Filed June 28, 1928 I I gwuaflot Ja wob S't Get. 16, 1928.

uNiTEo STATES PATE NT OFFICE;

JACOB STANDER, OF BROOKLYN, NEW YORK.

Application filed. June 28,

My invention relates'to new and useful improvements in materials for making metal furniture and office partitions and more particularly to a composite material or panel from which furniture may be produced and the method of making same, the primary ob ject of the invention being to provid'e a prod not and means for making same Which Will utilize outer faces of metal between which is introduced a member of cellulosic material formed of any desired material such as wood, paste board, insulating board, beaver board or an other analogous material.

A fi irther object of the invention resides in producing a material of the character mentioned which will be particularly well adapted for use in the production of metal furniture or oflice partitions by reason of the fact that the same will be noise-proof, fire-proof, water proof and light in weight, and a further object resides in producing a composite material which will be no more expensive if not less expensive, to manufacture than the ordinary metal panels and the like used for the manufacture of metal furniture;

A further object of the invention resides in the improved method by which the cellulosic material and the metal are secured together to produce the composite panel.

A further object of the invention resldes in the production of a material which is capable of being produced in Various shapes, forms and sizes;

A further object resides in providing a material which is simple and durable in construction, comparatively inexpensive to manufacture, and one which will be exceptionally useful in practice.

With these and numerous other objects in view, my invention consists in the novel features of construction, combination and arrangement of parts as will be hereinafter re ferred to and more particularly pointed out in the specification and claims.

In the accompanying drawing, forming a part of this application:

Figure 1 is a perspective view of a bed constructed of material formed or produced in accordance with m 1 improved method;

Figure 2 is a fragmentary vertical section therethrough as seen on the line 2-2 of Figure 1; and

Figure 3 is a sectional perspective view of a segment of the material produced in accordance with my improved method.

In recent years, metal furniture has become til 1928. Serial No. 289,067.

very popular by reason of the fact that it is quite sanitary and has been made in colors, shapes and designs which are more or less desirable, but it has been found that there are disadvantages connected with the ordinary metal furniture in that heavy metal is necessary and the sound of metal is undesirable to the user. Even though a piece. of furniture mayappear by reason of its shape and color to be constructed of wood, if when struck the sound of metal is discovered, it is most distasteful.

I have, after years of experience and experimental work, discovered a material and method of producing the same which will overcome the many difiiculties encountered in the use of the ordinary metal used for the manufacture of furniture and indescribing this product and the method of making the same, I shall refer to the drawing in which similar reference characters designate corresponding parts throughout the several views.

For convenience, I have illustrated in Figure 1 a bed which is constructed of my improved material, but, of course, it will be understood that .any other piece of furniture or structure may be constructed of this material and in further describing the material, I shall refer to the same as a panel, inasmuch as the material is made up usually in sheets or panels. The numeral 1 designates a member formed of cellulosic material and it may be any one of a number of materials, such as wood, insulating board, .pa-ste board, beaver board or any other analogous products now known to the trade. In this connection, I do not wish to be limited to any particular material, inasmuch as I have found that any of the materials hereabove named may be equally well utilized for the purpose desired. To the opposite faces of this member 1 are applied the metal sheets or layers 2 and 3, respectively, which completes the material which is most well'a-dapted for the urposes-desired, but the particular method of applying and securing these sheets of metal to the central cellulosic member 1 is most important and essential to the effective operation of the invention and the method of accom lishing this will be described in detail here low.

Many efforts have been made to secure sheets of metal to some sound-deadening material, but this has not been effectively accomplished for the reason that no proper and effective means for securing the metal to such materials had been produced. As stated above, I have discovered, after years of experience, the method and means for efiectively securing metal to a celluloslc ma ,terial which will not only withstand heat in a baking process but which will under such baking more effectively and 'posltively secure the elements together.

In carrying outmy method-to bring about the results desired, the cellulosic material, suchas insulating board, beaver board or any other material, is first treated wlth any desired chemical to harden the same as by .applying silicate of soda to the surfaces of I the material which closes the pores ofthe latter, the hardening step being particularly desirable when insulating or beaver board or the like is used, in order to cause the paper and other particles of which the same is formed to closely adhere to one another and harden in general. Following this treatment of the cellulosic material, the latter is allowed to drythoroughy under normal conditions.

Sheets of thin metal, as for instance, I

gauge metal or another gauge desired, are provided and one'faceof each sheet,"wh1ch becomes the innervface thereof when applied to use, i's thoroughly cleansed .w1th vinegar to removeqall surface polish and other extraneous matter thereon.'* These sheets so cleansed arethen allowed to dry under normal conditions.

I then'produceja varnish known asa phenol resin varnish otherwise known under the trade name of bakelite, composed of-approximately, of synthetic resin, which,

' is a condensation product of phenol and formaldehyde, 24% ac'etoneyand 21% of denatured alcohol byweight. The celluloslc .material and the inner cleansed faces of the sheets ofmetal arev then treated withthis phenol 'resin varnish by applying the latter with abru sh thereto, both faces of the cellu- V losic material being covered with this varnish. While wet with this varnish, the sheets of metal are applied to opposite faces of the j cellulosic material and placed under pressure I with clamps or other similar devices and im- I ,m'ediatelyplaced-in a'bakingove'n. [Heat of f250=to 300 -.-F. is applied thereto and this baking process is continued for approximately one hour. This dries out the elements of a the composite material and at the same time 1 causessaid elements to become adhered to-- gethe'r' and form one composite element g .Thefcomposite material is then removed manufactured into furniture or tions or otherwise,

from the oven, allowed to cool'and is then office partias may be desired, where-- upon the same is painted or lacquered, as

usual, and-the finished product again laced in, the baking oven with heat applled at 300 F. for approximately one hour. When removed, another coat of varnish may be applied and if necessary, additional baking processes may be carried on as found desirable. It has been found that through the particular treatment glven the elements forming my composite material, the method into any shape for any desired purpose- The metal sheets 2 and 3 are of very thin gauge metal and the thickness of the composite panel ma bevaried by increasing or decreasing the t ickness of the cellulosic member 1. This cellulosic'member produces a material which is sound-proof, and through the par ticular treatment of said; member and the use of the metal sheets, the composite material is also water-proof, fire-proof and sanitary.

been encountered in efforts to. produce a com posite panel by reason of the fact that no effective method has been discovered for securing metal to a sound proof or cellulosic ma- As statedabove, the greatest difficulty has terial. By m improved method,-these difii culties have. een definitely and positively overcome and it will be. seen that I have provided a simple, inexpensive. and. efliclent means for carrying out the objects of the invention.

Moreover,

the'material producedunder improved method is so light in weight that a panel thereof which isone-fourthof an inch 7 I in thickness will weigh no more than a similar size panel ofnumber 20 gauge regular I ns While I have particul'arly described the elesheet metal. 1

ments best adapted to perform the functions of my invention as set forth, it is obvious that various'changes in form, proportion and in a the minor details of COIISiJIUCtlOIlmay be resorted to without departing from the. spirit or sacrificing any of the'principles of the invene ti f Havingdescribed my invention, what I claim is: I v

1. A method of making a composite panel comprising a memberof,cellulosic'material and a metal facing, which. consists in first and said cellulosic member when dry with a phenol resin varnish, applying under pressure said facing to the member while wet and bakin the same at a high temperature.

2. method vofma'kin a composite panel comprising a member ofcellulosic material and metal facings, which consists in first.

treating the cellulosic member to harden the same, then treating one face of said facing treating the cellulosicjmember to harden the same, allowing the treated member to (1 under normal conditions, then treating the inner opposed faces ofthe metal facings and said cellulosic member-.when dry with a phenol resin varnish, applying under pressure said facings to the cellulosic member while wet and baking the same at a high temperature.

3. A method of making a composite panel comprising a member of cellulosic material and a metal facing, which consists in first treating the cellulosic member to harden the same, allowing the treated member to dry, then treating one face of said facing and said cellulosic member when dry with a phenol resin varnish composed of synthetic resin,

acetone and denatured alcohol, applying under pressure said facing to the cellulosic member while wet and baking the same at a high temperature.

4. A method of making a composite panel comprising a member of cellulosic material and a metal facing, which consists in first treating the cellulosic member to harden the same, allowing said treated member to dry, then treating one face of said facing and said cellulosic member when dry with a phenol resin varnish, applying under pressure said facing to the member while wet and baking the same at a temperature of 300 F.

In testimony whereof I aflix my signature.

JACOB STANDER. 

